Download JA3000S-E INSTALLATION, OPERATION AND MAINTENANCE

WE ARE HERE TO SURPRISE
JA3000S-E
Service scissor Lift
Lifting Capacity: 3000KG
INSTALLATION, OPERATION
AND MAINTENANCE MANUAL
ORIGINAL INSTRUCTION
Read this entire manual carefully and completely before installation and operation of the lift.
WE ARE HERE TO SURPRISE
INDEX
1. Important safety instructions……………………………….…5~8
1.1 Important notices
1.2 Qualified personnel
1.3 Danger notices
1.4 Condition notices
1.5 Warning signs
1.6 Sound level
1.7 Training
2. Overview of the lift………………………………………………..8
2.1 General descriptions
2.2 Technical data
2.3 Construction of the lift
3. Installation instructions………………………………………….9~11
3.1 Preparations before installation
3.1.1 Tools and equipments needed
3.1.2 A list for parts checking
3.1.3 Ground conditions
3.2 Precautions for installation
3.3 Installation
3.4 Items to be checked after installation
4. Operation instructions…………………………………………11~14
4.1 Precautions
4.2 Descriptions of control box
4.3 Flow chart for operation
4.4 Operating instructions
4.5 Emergency lowering in case of no power
5. Trouble shooting………………….…………………………… 15
6. Maintenance……………………………………………………..16
7. Annex…………………………………………………….………..17~28
Annex1, Packing list of the whole lift
Annex2, Overall diagram
Annex3, Hydraulic working system
Annex4, Wiring diagram
Annex5, Separate diagrams for the lift
Annex6, Spare parts list
Annex7, Size and weight requirements on vehicles
2
WE ARE HERE TO SURPRISE
User’s Records
Fill the following blanks with the information on the nameplate.
Model No. : ____________________________
_
Serial No. :___________________________
Production Date:______________________
__
The following specially trained people are permitted to operate
and maintain this lift.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
3
WE ARE HERE TO SURPRISE
Installation Records
Model No. : _________________________
Serial No. : _ _ ____________________
Customer’s Name:
Installation Date:
___
___
___
______________________ ___ ___
__________________
__________
Declaration
The above mentioned lift has been correctly installed and all its
functions including the reliability of safety locks have passed strict
tests. Therefore we hereby declare that this lift is in normal working
condition when installation finished.
Installation date
Installer’s signature
------------------
----------------
User’s signature
---------------4
WE ARE HERE TO SURPRISE
1. IMPORTANT SAFETY INSTRUCTIONS
1.1 Important notices
JEMA AUTOLIFTE will offer two-year's quality warranty，during which any quality problem will be properly solved to the user's
satisfaction. However, we will not take any responsibility for whatever bad consequence resulted from improper installation and
operation, overload running or unqualified ground condition.
This service scissor lift is especially fit for tire service or other quick service around vehicles. Users must always bear in mind
that this JA3000S-E is specially designed for lifting cars or other vehicles, so never use it for any other purposes. Otherwise, we,
as well as our sales agency, will not bear any responsibility for accidents or damages of the lift.
Make sure to pay careful attention to the label of the lifting capacity attached on the lift and never try to lift cars with its weight
beyond. Read this manual carefully before operating the machine so as to avoid economic loss or personnel casualty incurred
by wrong operation. Without our professional advice, users are not permitted to make any modification to the control unit or
whatever mechanical unit.
1.2 Qualified personnel
1.2.1 Only these qualified staff, who have been properly trained, can operate the lift.
1.2.2 Electrical connection must be done by a competent electrician.
1.2.3 People who are not concerned are not allowed in the lifting area.
1.3 Danger notices
1.3.1 Do not install the lift on any asphalt surface.
1.3.2 Read and understand all safety warnings before operating the lift.
1.3.3 Do not leave the controls while the lift is still in motion.
1.3.4 Keep hands and feet away from any moving parts. Keep feet clear of the lift when lowering.
1.3.5 Only these properly trained personnel can operate the lift.
1.3.6 Do not wear unfit clothes such as large clothes with flounces, tires, etc, which could be caught by moving parts of the lift.
1.3.7 To prevent evitable incidents, surrounding areas of the lift must be tidy and with nothing unconcerned.
1.3.8 The lift is simply designed to lift the entire body of vehicles, with its maximum weight within the lifting capacity.
1.3.9 Always insure the safety locks
are engaged before any attempt to work near or under the vehicle. Never remove safety
related components from the lift. Do not use if safety related components are damaged or missing.
1.3.10 Do not rock the vehicle while on the lift or remove any heavy component from vehicle that may cause excessive weight
shift.
1.3.11 Check at any time the parts of the lift to ensure the agility of moving parts and the performance of synchronization.
Ensure regular maintenance and if anything abnormal occurs, stop using the lift immediately and contact our dealers for help.
1.3.12 Lower the lift to its lowest position and do remember to cut off the power source when service finishes.
1.3.13 Do not modify any parts of the lift without manufacturer’s advice.
1.3.14 If the lift is going to be left unused for a long time, users are required to:
a. Disconnect the power source;
b. Empty the oil tank;
c. Lubricate the moving parts with hydraulic oil.
1.4 Condition notices
Generally, this machine will be installed on the following conditions:
1.4.1 supply voltage:0.9-1.1 nominal supply voltage
1.4.2 source frequency:0.99-1.01 nominal frequency
5
WE ARE HERE TO SURPRISE
1.4.3 Ambient temperature: 50°C - 400°C
1.4.4 Altitude:shall be at altitudes up to 1000m above mean sea level
1.4.5 Relative humidity: not exceed 50% at 400°C
1.4.6 Atmosphere: Free from excessive dust, acid fume, corrosive gases and salt.
1.4.7 Avoid exposing to direct sunlight or heat rays which can change the environmental temp.
1.4.8 Avoid exposing to abnormal vibration.
1.4.9 Electrical equipment shall withstand the effects of transportation and storage temperature within a range of -25°C to 55°
C and for short periods not exceeding 24 hours at up to +70°C
Attention: For environment protection, please dispose the disused oil in a proper way.
6
WE ARE HERE TO SURPRISE
1.5 Warnings (Read and understand all safety warnings before operation)
All safety warning signs attached on the machine are for the purpose of drawing the user’s attention to safety operation. The
labels must be kept clean and need to be replaced when they are worn-out or have dropped. Read the explanations of the
labels carefully and try to memorize them.
7
WE ARE HERE TO SURPRISE
1.6 Sound Level
The sound emitted from the lift should not exceed 65DB. For the sake of your health, we suggest putting a noise detector in
your working area.
1.7 Training
Only properly trained people are allowed to operate the lift. We are quite willing to provide professional training for the users
when necessary.
2. Overview of the lift
2.1 General descriptions
The lift is driven by an electro-hydraulic system. The gear pump delivers hydraulic oil to oil cylinders and pushes upwards their
pistons to raise the platforms. For this model, we offer two safety solutions: one with anti-surge valve in hydraulic system to
prevent sudden drop down of platform in case the oil hose broke, the other with anti-surge valve and an extra pneumatic safety
lock.
Pneumatic safety lock.
2.2 Technical data
Model
Lifting capacity
Lifting time
Lifting height
Power supply
JA3000S-E
3000KG
30S
1000mm
220V/240V,single phase
Weight on JA3000S-E = 500 KG
2.3 Construction of the lift
8
WE ARE HERE TO SURPRISE
3. Installation instructions
3.1 Preparations before installation
3.1.1 Tools and equipments needed
√ Electrical drill
√ Open wrenches
√ Screw drivers
√ Adjustable spanners
√Inner hexagon spanners
3.1.2 List for parts checking ---Annex 1（Packing list）
Unfold the package and check if any parts missed as per Annex 1. Do not hesitate to contact us in case any parts missed, but if
you do not contact us and insist installing upon the lack of some parts, JEMA AUTOLIFTE as well as our dealers will not bear
any responsibility for this and will charge for any parts subsequently demanded by the buyer.
3.1.3 Ground conditions
The lift should be fixed on a smooth and solid concrete ground with its strength more than 3000psi, tolerance of flatness less
than 5mm and minimum thickness of 200mm. In addition, newly built concrete ground must undergo more than 28days’ cure
and reinforcement.
3.2 Precautions for installation
3.2.1 Joints of oil hose must be firmly connected in order to avoid leakage.
3.2.2 All bolts should be firmly screwed up.
3.2.3 Do not place any vehicle on the lift in the case of trial running.
3.3 Installation
Step 1: Remove the packaging and take the two mechanical assemblies and the control box to the designated
installing place. Please do read and understand this manual thoroughly before next step.
9
WE ARE HERE TO SURPRISE
Step 2: Connect the oil hose to the pump assembly with a proper wrench, it has no effect which side the oil hoses are
connected to. ( Make sure the hose end is clean).
Step3: Connect the limit switch wires to the wiring terminals in the control box.
Make sure to connect NO.1 wire with
NO.1 terminal , NO.2 wire with NO.2 terminal and so forth.
Step4: Link the air hose to compressed air source. (This step is only for the type with pneumatic safety lock)
8mm connection direct to compressor
6mm connection for the lift
Step5: Adjustment of lowering speed
Before the lift is used, the user must be sure to adjust the lowering speed properly according to user's request.
It is important to bear in mind that the lift has a maximum capacity of 3000 kg. Which means the lift is not lower
too fast with max capacity.
10
WE ARE HERE TO SURPRISE
Lowering speed is adjusted on the screw on the right hand side of the engine. The adjustment is done as follow,
the user rise the lift, and then starts to lower the lift when the screw is screwed in the lower speed will decrease and if the user
screw the screw out the lowering speed will increase NB. Remember to adjust before load of car and it is important to
remember the lift will lower much faster when there is load on the lift.
A explanation video how to adjust lowering speed and pump pressure can be found here:
jemaautolifte.dk/adjustment_of_220V_engine.wmv
Step 6: Fix the base frame. (Optional )
JA3000S-E is portable. In other words users may use it without having it placed and fixed on the ground. Nevertheless, if you
want to have it fixed, do fix it on a smooth and solid concrete surface.
Step 7: Trial testing with load. (Do not use cars for trial testing)
Load applied shall not exceed 2500KG. Add 10L of hydraulic oil when all oil hose are gathered.
This step is of particular importance for it can check if the oil hose and air hose are well connected. Connections are qualified
when there is no abnormal sound or leakage after having been tested for 2 or 3 times.
3.4 Items to be checked after installation
S/N
Check items
1
Are two platforms on the same level?
2
Are oil hoses well connected?
3
Are electrical connections correct?
4
Do valves on the pump assembly leak?
YES NO
4. Operation instructions
4.1 Precautions
4.1.1 Check all the joints of oil hose. Only when there is no leakage, the lift can start work.
4.1.2 The lift, if its safety device malfunctions, shall not be used.
4.1.3 The machine shall not lift or lower an automobile if its center of gravity is not positioned midway of the rising platforms
Otherwise, the JEMA AUTOLIFTE as well as our dealers will not bear any responsibility for any consequence resulted thereby.
4.1.4 Operators and other personnel concerned should stand in a safety area during lifting and lowering process.
4.1.5 When platforms rise to the desired height, switch off the power at once to prevent any wrong operation done by
unconcerned people.
4.1.6. Make sure the safety lock of the lift is engaged before start working under the vehicle and no people under the vehicle
during lifting and lowering process.
11
WE ARE HERE TO SURPRISE
4.2 Descriptions of control box
4.3 Flow chart for operation
Start
Start
Turn on the power switch
Turn on the power switch
Press
Press
the
the
DOWN
UP button
button
Press the UP button
Press the DOWN button
Motor drives the gear pump work
The lift is lowered
Cylinder piston drives the platform move up
The lift is raised
12
WE ARE HERE TO SURPRISE
4.4 Operation instructions
Remark: Only authorized staff can adjust the system pressure on the power unit.
Raise the lift
1.Make sure that you have read and understood the operation manual before operation.
2.Drive and park the vehicle midway between two platforms.
3.Place the four rubber pads under the prop-points of the vehicle and ensure car’s gravity have fallen on the rubber pads.
4.Press the UP button on the control box until rubber pads have touched the prop-points of vehicle.
5. Keep on pressing the UP button to lift the vehicle a bit higher from the ground and check again if the vehicle is in a safe
position.
6. Having raised the vehicle to the required height, operators must check again the safety issue before performing maintenance
or repair work,
Lower the lift
1.Switch on.
2.Press the UP button release the safety lock, then press the DOWN to lower the lift, to the wanted height.
3.If the lift is on minimum drive away the vehicle.
4.5 Emergency lowering in case of no power
The safety lock is not engaged :
a. Tie up the safety teeth on both sides with rope; pull upward the rope making the safety teeth unlocked.
b.Having the safety teeth unlocked, manually loose the core of electro-magnetic valve on the pump assembly. This screw
decides the lowering speed. The screw is going in, the lift will lower slower, the screw is going out the lift will lower fas ter.
The safety lock is engaged:
a.Screw off the fitting (opposite to the oil out-let) to connect a hand pump.(Optional)
13
WE ARE HERE TO SURPRISE
b.Connect the hydraulic assembly with the optional hand pump. Press down the handle of the pump to raise the platforms
to have the safety teeth unlocked.
c.Pull up the safety teeth and tie up them up.
14
WE ARE HERE TO SURPRISE
5. Trouble Shooting
ATTENTION: If the trouble could not be fixed by yourself, please do not hesitate to contact us for help .We will offer our service
at the earliest time we can. By the way, your troubles will be judged and solved much faster if you could provide us more details
or pictures of the trouble.
TROUBLES
CAUSE
SOLUTION
The wire connection is loose.
Check and make a good connection.
Motor does not run and
The motor is burnt
Replace it.
will not raise
The limit switch is damaged or the wire
Connect it or adjust or replace the limit
connection is loose.
switch.
The motor run reversely.
Check the wire connection.
Overflow valve is loose or jammed.
Clean or adjust it.
The gear pump is damaged.
Replace it.
Oil level is too low.
Add oil.
The oil hose became loose.
Tighten it.
The cushion valve became loose or jammed.
Clean or adjusts it.
The oil hose leaks.
Check or replace it.
The oil cylinder is not tightened.
Replace the seal.
The single valve leaks.
Clean or replace it.
The overflow valve leaks.
Clean or replace it.
Electrical unloading valve leaks.
Clean or replace it.
The oil filter is jammed.
Clean or replace it.
Oil level is too low.
Add oil.
Motor runs but will not
raise
Platforms go down slowly
after being raised
Raising too slow
The overflow valve is not adjusted to the right
position.
The hydraulic oil is too hot ( above 45°).
15
Adjust it.
Change the oil.
WE ARE HERE TO SURPRISE
Lowering too slow
The seal of the cylinder is abraded.
Replace the seal.
The throttle valve jammed.
Clean or replace.
The hydraulic oil is dirty.
Change the oil.
The anti-surge valve jammed.
Clean it.
The oil hose jammed.
Replace it.
6. Maintenance
Easy and low cost routine maintenance can ensure the lift work normally and safely. Following are requirements for routine
maintenance. You may choose the frequency of routine maintenance by consulting your lift’s working conditions and time.
THE FOLLOWING PARTS NEED TO BE LUBRICATED
S/N
Description
1
Small idler wheel
2
Rotor shaft
3
U-shape block
4
Safety shaft
5
Rotor shaft of oil tank
6
Slider
6.1. Daily checking items before operation
The user must perform daily check. Daily check of safety lock system is very important – the discovery of device failure before
action could save your time and prevent you from great loss, injury or casualty.
·Before operation, judge whether the safety lock is engaged by sound.
·Check whether oil hose well connected and whether it leaks or not.
·Check the electrical system.
·Check whether plug bolts firmly screwed.
·Check if safety teeth and safety block matched well or not.
6.2.Weekly checking items
16
WE ARE HERE TO SURPRISE
·Check the flexibility of moving parts.
·Check the working conditions of safety parts.
·Check the amount of oil left in the oil tank. Oil is enough if the platforms can be raised to highest position.
Otherwise, oil is insufficient.
·Check whether plug bolts firmly screwed.
6.3. Monthly checking items
·Check whether plug bolts firmly screwed.
·Check the tightness of the hydraulic system and screw firm the joints if it leaks.
6.4. Yearly checking items
·Empty the oil tank and check the quality of hydraulic oil.
·Wash and clean the oil filter.
If users strictly follow the above maintenance requirements, the lift will keep in a good working condition and
meanwhile accidents could be avoided to a large extent.
7. ANNEX
Annex 1，Packing List of the whole lift
S/N
Name
Qty
1
JA3000S-E Mechanical Assembly
2
2
Movable control box with hydraulic system
1
2.1
Wheel
2
2.2
Connection kit
1
2.3
All directional wheel
1
3
Feet protector
2
4
Connection pipe
2
5
Inside hex screw
32
6
Rubber pad
4
17
WE ARE HERE TO SURPRISE
Annex2，Overall diagram
18
WE ARE HERE TO SURPRISE
Annex3，Diagram for pneumatic system.
1.
Air filter
2.
Pneumatic solenoid valve
3.
Pneumatic cylinder for the main platform
4.
Pneumatic cylinder for the assistant platform
19
WE ARE HERE TO SURPRISE
Annex 4，Hydraulic working system
1.
Driving cylinder
2.
Assistant cylinder
3.
Electrical release valve
4.
Lowering throttle valve
5.
Motor
6.
Coupling
7.
Gear pump
8.
One-way valve
9.
Over-flowing valve
10. Anti-surge valve
11. Cushion valve
12. Emergent unloading valve
Annex5, Wiring diagram
Single phase
20
WE ARE HERE TO SURPRISE
21
WE ARE HERE TO SURPRISE
22
WE ARE HERE TO SURPRISE
Annex 6，Separate diagrams for the lift
For the pump:
S/N
23
DESCRIPTION
QTY
1
MOTOR
1
2
HYDRAULIC BLOCK
1
3
OVERFLOW VALVE
1
4
FITTING
2
5
CUSHION VALVE
1
6
ABSORBING OIL PIPE
1
7
OIL FILTER
1
8
THROTTLE VALVE
1
9
OIL HOSE TIE-IN
1
10
ELECTRICAL UNLOADING VALVE
1
11
SINGLE-WAY VALVE
1
12
GEAR PUMP
1
13
OIL TANK
1
14
OIL TANK COVER
1
15
OIL BACK PIPE
1
WE ARE HERE TO SURPRISE
For the lift
S/N
Name
Drawing #/Spec.
Qty
1
Ramp assembly A
JA3000S-E-A22
4
2
Platform assembly B
JA3000S-E-A20
2
3
Small idler wheel
JA3000S-E-A8
8
4
Shaft
JA3000S-E-A9
4
5
Circlip for the shaft
D25
4
6
Swing shaft
JA3000S-E-A17
2
7
Self-lock screw
JA3000S-E-A18/ M27
8
8
X shape shaft
JA3000S-E-A7
2
9
Oilless bearing
3045
12
10
Security shaft
JA3000S-E-A5-B14
2
11
Driving assembly
JA3000S-E-A5
2
12
Nylon Slider
JA3000S-E-A5-B6
2
13
Limit switch
14
Safety lock holder
JA3000S-E-A5-B15
1
15
Feet protector
JA3000S-E-A1-B7
2
16
Inside hex screw
M10x35
8
17
U-shape block
JA3000S-E-A4
8
18
Right base assembly
JA3000S-E-A2
1
19
Fasten shaft for oil tank
JA3000S-E-A16
2
20
Oil cylinder(right)
JA3000S-E-A15-B2
1
21
Guiding plate B
JA3000S-E-A23
1
2
24
Note
WE ARE HERE TO SURPRISE
22
Drive assembly
JA3000S-E-A3
1
23
Nylon slider
JA3000S-E-A5-B6
2
24
Prop-trough
JA3000S-E-A25-B2
1
25
Left base assembly
JA3000S-E-A1
1
26
Air tank
CQ2B32x20
2
27
Feet protector
JA3000S-E-A1-B7
1
28
Safety lock holder
JA3000S-E-A5-B15
1
29
Oil cylinder (left)
JA3000S-E-A15-B1
1
30
Shaft to fasten platforms
JA3000S-E-A21
4
31
Oilless bearing
2525
4
32
Circlip for the shaft
D25
8
33
Small idler wheel
JA3000S-E-A22-B5
8
34
Prop assembly
JA3000S-E-A22-B6
4
35
Shaft of guiding plate
JA3000S-E-A22-B4
8
36
Platform assembly A
JA3000S-E-A19
1
25
WE ARE HERE TO SURPRISE
Annex 7.Spare parts list
Spare parts list---electrical system
S/N
Material No.
1
321001
2
322008
3
342021
Name
Power
switch
Button
Power
indicator
Spec.
Qty
Unit
LW26GS-20/04
1
Pcs
Y090-11BN
1
Pcs
AD17-22G-AC24
1
Pcs
1
Pcs
1
Pcs
DZ47-63 C32/2P
1
Pcs
DZ47-63 C1/1P
1
Pcs
DZ47-63 C3 /1P
1
Pcs
ME8104
1
Pcs
JBK3-40VA380V-24
4
320078
320084
Transformer
V
JBK3-40VA220V-24
V
5
6
330004
AC contactor
327004
Circuit
327002
breaker
7
327016
8
327003
9
321024
Circuit
breaker
Circuit
breaker
Limit switch
CJX2-1210/AC24
DZ47-63 C16/3P
26
Pic.
WE ARE HERE TO SURPRISE
S/N
Material No.
Name
Spec.
10
321032
Limit switch
11
322010
12
336012
13
335007
Capacitor
4700UF/50A
1
Pcs
14
326009
Relay
LY2NJ/DC24
1
Pcs
15
326011
Relay holder
PTF-08A-E
1
Pcs
18
328004
Control box
190*430*135
1
Pcs
Emergency
stop
Bridge
rectifier
Qty
Unit
8108（TZ8108）
2
Pcs
Y090-11ZS/red
1
Pcs
KBPC5A-35A
1
27
Pcs
Pic.
WE ARE HERE TO SURPRISE
Spare parts list---machine part
S/N
Name
Drawing #/Spec.
Qty
1
Self-lock screw
JA3000S-E-A18/ M27
8
2
Security shaft
JA3000S-E-A5-B14
2
3
Nylon Slider
JA3000S-E-A5-B6
2
4
Limit switch
5
Safety lock holder
JA3000S-E-A5-B15
1
6
Feet protector
JA3000S-E-A1-B7
2
7
U-shape block
JA3000S-E-A4
8
8
Oil cylinder (right)
JA3000S-E-A15-B2
1
9
Nylon slider
JA3000S-E-A5-B6
2
10
Air cylinder
CQ2B32x20
2
11
Safety lock holder
JA3000S-E-A5-B15
1
12
Oil cylinder (left)
JA3000S-E-A15-B1
1
1
Annex8，Size and weight requirements on vehicles
Model
JA3000S-E
A
B
C
D
E
F
G
(mm)
(mm)
(mm)
(T)
(T)
(T)
(T)
1600
2000
110
1.8
1.2
1.2
1.8
28
Note